REMOVAL AND INSTALLATION


caution When the engine assembly is replaced, register the injector identification code, perform the small injection quantity learning and perform the supply pump correction learning (Refer to GROUP 00 - Precautions before Service, What the Common Rail Engine Learns ).
Pre-removal Operation
  • Hood Removal.
  • Engine Oil Draining (Refer to GROUP 12 - On-vehicle Service, Engine Oil Replacement ).
  • Air Cleaner Assembly Removal (Refer to GROUP 15 - Air Cleaner ).
  • Battery Tray Stay Removal (Refer to GROUP 54A - Battery ).
  • Radiator Removal (Refer to GROUP 14 - Radiator ).
  • Cooling Fan and Fan Clutch Assembly Removal (Refer to GROUP 14 - Cooling Fan ).
  • Manifold Absolute Pressure Sensor Removal (Refer to GROUP 11H - Solenoid Valve and Vacuum hose ).
  • Front Deck Panel Removal.

 Post-installation Operation
  • Front Deck Panel Installation.
  • Manifold Absolute Pressure Sensor Installation (Refer to GROUP 11H - Solenoid Valve and Vacuum hose ).
  • Cooling Fan and Fan Clutch Assembly Installation (Refer to GROUP 14 - Cooling Fan ).
  • Radiator Installation (Refer to GROUP 14 - Radiator ).
  • Battery Tray Stay Installation (Refer to GROUP 54A - Battery ).
  • Air Cleaner Assembly Installation (Refer to GROUP 15 - Air Cleaner ).
  • Engine Oil Refilling (Refer to GROUP 12 - On-vehicle Service, Engine Oil Replacement ).
  • Air Bleeding from Fuel Line (Refer to GROUP 13E - On-vehicle Service, Evacuation of Air from Fuel Line ).
  • Hood Installation.




Removal steps


1.
 Engine cover


·
 Control wiring harness connection


·
 Battery wiring harness connection
<<A>>
·
 Power steering oil pump assembly (Refer to GROUP 37 - Power Steering Oil Pump Assembly ).
<<B>>
·
 A/C compressor and clutch assembly (Refer to GROUP 55A - Compressor Assembly ).


·
 Brake booster vacuum hose connection (Refer to GROUP 35A - Master Cylinder Assembly and Brake Booster Assembly ).


·
 Heater piping hose connection (Refer to GROUP 55A - Heater Hose ).


2.
 Fuel hose D connection


3.
 Fuel return hose connection


·
 Transmission assembly (Refer to GROUP 22A - Transmission Assembly ) <M/T-2WD>.


·
 Transmission assembly (Refer to GROUP 22A - Transmission Assembly ) <M/T-4WD>.


·
 Transmission assembly (Refer to GROUP 23C - Transmission Assembly ) <A/T-2WD>.


·
 Transmission assembly (Refer to GROUP 23C - Transmission Assembly ) <A/T-4WD>.


4.
 Engine mounting bolt
<<C>>
 >>A<<
 5.
 Engine assembly

REMOVAL SERVICE POINTS

<<A>> POWER STEERING OIL PUMP ASSEMBLY REMOVAL
1.With the hose installed, remove the power steering oil pump assembly from the bracket.
2.After removing the power steering oil pump assembly, secure it with a cord in the location where the removal and installation of the engine assembly cannot be hindered.

<<B>> A/C COMPRESSOR AND CLUTCH ASSEMBLY REMOVAL
1.With the hose installed, remove the A/C compressor and clutch assembly from the bracket.
2.After removing the A/C compressor and clutch assembly, secure it with a cord in the location where the removal and installation of the engine assembly cannot be hindered.

<<C>> ENGINE ASSEMBLY REMOVAL
1.Check that all cables, hoses and wiring harness connectors are disconnected from the engine
2.Lift the special tool sling chain set (MB991683) and chain block slowly to remove the engine assembly upwards from the engine compartment.

INSTALLATION SERVICE POINT

>>A<< ENGINE ASSEMBLY INSTALLATION
1.Use special tool sling chain set (MB991683) and chain block to lift the engine assembly in the same manner as removal.
2.Install the engine assembly, being careful not to pinch the cables, hoses or wiring harness connectors.